Machine for making solderless electrical connections



Oct. 24, 1950 `s`. M. wEls'BERG MACHINE FCR MAKING SOLDERLESS ELECTRICAL CONNECTIONS Filed June zal, 1 946 4 Sheets-Sheet 1 JdngMWeberg BY v Oct. 24, 1950 s. M. wl-:lsBERG MACHINE FOR MAKING SOLDERLESS ELECTRICAL CONNECTIONS 4 Sheets-Sheef l2 Filed June 22, 1946 C- 24 1950 s. M. wElsBERG MACHINE FOR MAKING soLDERLEss ELECTRIAL CONNECTIONS Filed June 22, 194e 4 Sheets-Sheet 3 lNvENToR Sia/negjll. Weiserg' Oct. 24, 1950 s. M. wElsBx-:RG

MACHINE FOR MAKING SOLDERLESS ELECTRICAL CONNECTIONS Filed June 22,v 1946 4 Sheets-Sheet 4 yidney M /f'z'sjvezy INVENTOR BY n 0?.)

ATT R N EY Patented 24, 195.10

* UNITED Y STATE-s PATENT AOrifice v I e y '2.526,7174# Y i' A MACHINE ,FOR MAKINQ; SoLDERLEss vELECTRICAL onnnc'rions Sidney M. VWeisberg",` Newark, J., assigner t6 VAllied Electric Products, Inc., Irvington, N. J.;

a corporation of New Jersey Applicationjuneaa 194e, serial Ne. 678,557

"The invention here Y manufacture of solderless wire terminals and connectors of the type disposed in cope'nding patent application Serial No.V 634,704, led'December 13, 1945, AnOW Patent' 2,456,601, issued Dec. 14,1948.

In the type of connector referred to, the wire is mechanically and electrically secured 'without the use of solder, by entering it ina larger size opening in a -terminal or connector member and then -driving a wedging fastener in the nature of` a pin or tack, into the `opening alongside the wire, to bind and interlock the wire in positive, Ifixed engagement 4with the wall of the opening. vThe. main purposes of the present invention are to accomplish the practical 'and eliicientv production of such connections on a commercial scale, at a rapid rate and at low cost. Special objects are 'to provide simple, vinexpensive, easily operated 'mechanism for accomplishing the assembling and fastening 'functions peculiar to this particular 'form of connection.

Other objects attained by the invention and the 'novel 'features 'oi construction kthrough which all purposes ofthe invention areattainedare set forth or will appear inthe course of the following specification.

The drawings accompanying and forming-,part of 'the specification illustrate certain present pre- 'ferred embodiments of thefinvention. V'Structure and arrangement, howeven'may'be modied Iand changed as regards the present illustration, "all within 'the true intent and broad scope of the invention as hereinafter dened and claimed.

Fig. 1 in the drawingsiis abroken front elevation 'of ka machine for assembling the connectors and showing a fluorescent VV'starter switch in position 'for havingthe wires alxed to the terminals "of the same; f

Fig. 2 is an-'enlarged broken-sectional view-illustrating the completion of -theoperation on the starter switch shown in Fig. '1; f f

"Fig 3 is a. brokerifside elevation of the'machine illustrated in Fig. "1j I l Y I Figs 4 and'ii 'are broken ffront and side views, respectively,v of a modied -type fof machine lin which the vpunches 'are rotated toeffect atw'isting-orf `or shearing `'ci the excess Awireends;

Fig. Y6` is la broken, vpart-sectional detail of-a modification in which 'only partialrotation is 'imparted to the drivingpunches; v

Fig. 7 is a broken sectional detail illustrating use of a punch arranged to cooperate with the terminal vto shear oirthe loose wire ends;

Fig. 8 is a similar viewillustrating further modiflcations in the form of the terminal lore'orr- )rector memberand in the iform-or a-punch Y 7 claims. (01.21.24.203)

disclosed relates to the YFig;v 9 isa broken detail of another :crm ur wire severing punch.

The machine shown in Fig. 1 is designed for driving headed,Av tack-'like fastenings Ill, Fig. v2, intothe Vtubular terminals II of lfluorescent starterA switches I2 `vior securing in each terminal two wires I3 andl4. v

Accordingly, the4 machine is provided with a holder yI5 for the starter switch, which will line u p the Vterminals I.I with two Yof the pins Iii supported in a vertically movableholder I5, directly beneath a pair of punches I'I.

The holder I5 for the starter switch is shown carried by a vertically movable rod I8 actuated from a foot pedal, air cylinder, motor crank mechanism'or the like.

The ,-pin driving punches I1 in this rstrillustrated embodiment of the Vinvention lare adjust'- ably and rigidly secured as by Aset screws I9 in ,a rigid head 20. The fastenings I0 are fed to the holder l'from anelevatedhopper-ZI, down inclined guides 122. Amotor driven hopper wheel 23 lines the pins up in the upper ends of the guides 22 and the vertically movable pin holder I 6 at the bottom of the guides operates as a cut-off to release only two pins-at a'time into `position in the holder.

The front portion of the pin holder I6 is' made in relatively separable sections to provide pin holdingvnfgers v21| yieldably closed'by a spring 25 so as to open Yup to permit vpassage of the pins into the terminals Yunder the driving action of the punches I1.

VvThe-enlarged view, Fig. 2, shows how in addition fto-feipecting'the driving of the pins and the vsecuring of the vwires-the machine accomplishes lthe trimming-off-:orremval of excess wire I3', III',Y by forcin'g'fthe pins fa-r enough in the terininals-tocausethe heads 25 ofthe pins to bite or '-pin'ch''the'--wire against the convergently inclinedorbeveled surrounding walls 2l provided inthe-ends of the terminals. Y YThis pinching-oil action effected -by the heads of the fasteners-isgenerally sufficient because even if the vwiresare-not Yout entirely through,

' theywill be so weakened as to drop ofi inthe vslots 1'29 in 'the forward edge of the same positioned to receivethe re'ducedneck portions of the terminals, -andfshouldered at the top at 30 to provide seats or restsifor the enlarged or head portions 3I.o'f;the terminals. l

The body of the holder l below the locating plate is shown as recessed at 32, at opposite sides to provide clearance for the fingers in placing the switch in and removing it from the holder.

A vertically operable feed slide 33 is shown for lifting the pins up to the hopper wheel at the upper end of the inclined guides. This feed slide may be connected to operate automatically work and insertion of a new piece. In removing,

the part may be inspected to see Whether the loose wire ends have -been fully removed and if not, they may be shaken or broken loose With a light brushing movement. I

The assembly may be effected with a quick drive stroke, since the displacement of metal in the wires by the wedging and binding action of the pins may be relatively slight. While the force required in fastening dierent terminals may vary depending on relative location of the wires in the terminal passages, variations in size of the pins, etc., such variations are minor in character and are readily overcome by the action of the pins in wedging the wires more or less apart and into generally longitudinally aligned relation as the pins are driven.

Figs. 4 and 5 illustrate how the structure may be modied to accomplish a more certain separation and removal of loose wire ends, by causing the driving punches to rotate and thus act to sever or shear the excess wire.

In the illustration, the motor 34 for operating the hopper wheel is shown utilized for rotating the punches Il by rotatably supporting them at 35 in the head 20 and providing them at the upper ends with intermeshing gears 36 driven by gear 31 on the lower end of the motor shaft extension 38, the motor in this instance being mounted with its shaft vertical and coupled to the vertical shaft extension 38.

In the last described construction the punches may rotate continuously and both in the same or in different directions. These punches may be of enough larger diameter at their driving ends to extend beyond the heads 26 of the pins to engage and exert a shearing or tearing action on projecting end portions of the Wires. The time of engagement of the punches with the heads of the pins may be substantially instantaneous so that any twisting effect of the punches on the pins need not be disadvantageous, and this twisting moment may be an actual advantage in setting the pins more rmly in the terminals and into interlocking engagement with the Wires in the terminal passages.

Fig. 6 illustrates another embodiment of the machine in which the punches I1 have only a partial rotation, and that only at the end of the driving stroke.

For such purposes the punches arerrotatably mounted in the supporting head at 39 and have slight longitudinal movement in their bearings, limited by stop shoulders 40. Springs 4I thrust the punches to their projected position. Cam grooves 42 in the inner body portions of the punches, engaged by stationary pins 43, impart a slight nal twist to the punches as they are forced back in the driving operation, this rotary movement being determined by the cam slope and suicient to normally eifect the desired severance and separation of the loose Wire ends.

Fig. 7 is an enlarged view illustrating the feature of making the punch diameter suilicient for the corner edge of the punch to engage the conical socket 21 in the terminal head, substantially at the instant of fully setting the pin in the terminal, thus to act in a cut-off capacity to fully sever the surplus wire.

Fig. 8 illustrates another form of punch formed with a chisel edge 44 togo down over the head 26 of the pin and cooperate with the end face of the terminal 45 about the head to sever any protruding portions of wire.

The terminal 45 in the last illustration is shown as a at piece of metal to illustrate the point that the invention is applicable to various kinds of terminals other than those of the generally tubular form rst illustrated.

Fig. 9 illustrates another form of punch having a concave end 46 which may be toothed as in dicated at 41 to operate as a cutter when used in the rotating type of machine shown in Figs. 4 and- 5.

The machine and the method disclosed afford practical, high speed production of particularly strong and durable solderless connections. As shown in Fig. 2, the severance of excess wire in the conical cup or cavity in the end of the terg minal leaves the end surface of the terminal flush and smooth so that it will make. good contact in the receptacle or other device with which it may be intended to cooperate.

The severance of the excess wire may be either partial or complete, that is, the wire may be entirely cut off or only partially severed, in the latter instance to be removed by breaking off at the weakened section as by a simple brushing movement. i

While desirable, as illustrated in the present instance, to make two solderless connections at a time, the machine may be constructed to make one or any number of these connections at a time. v

The form of the electric terminal with which the Wire is connected may Vary, the invention being .applicable to make these solderless connections with any forms of electrical parts vor The word terminal, therefore, has

i minal, it will be realized that one or a number of wires may be secured ina terminal, after the manner of this invention.

While ordinarily the pin may be in the form of ametal tack, it should be understood that this pin need not be a headed member, and also that it need not be of metal, since the wire in being crushed against the side of the passage will be firmly bound in` electrical and mechanical connection with the terminal member.

, While the passage in which the wire is secured is shown as an opening extending entirely through the terminal, it will be realized that this wire opening or passage need not extend entirely through the member vwith which the wire is connected.

The members at the end of the punch which eiect the complete or partial severance of the wire or wires, as shown, 'may be companion shearing elements as between the end of .the punch 'and the yterminal member. or as between the end of'thepunch and thehead of the fasteneror between the head of the fastener and the end of the terminal, or the like. "Generally speaking, the invention isfof vbroad scope and the claims thereforeiare tolfbe construed, in a broad sense and 'the order as indiaited above. A u

, What'i'sclaimedis' A Y* l 1. A, machine for making 'solderless'lconnections for electric terminals having .wire receiving openings and comprising 'cooperating punch and holder members having v relative AVmovement'toward and away from each other, saidv Aholder member having means for positioning af terminal with a wire receiving opening therein in linewith said punch, a holder for a pin of a size which may be driven into binding engagement with a wire in v said passage, said pin holderbeing `arranged to temporarily support a pinbetw'een saidpun'ch and terminal holder member`s`an`d in linev with the Wire passage of the supported terminal, means for effecting relative movement of said punch and terminal holder members to accomplish the driving of a temporarily supported pin into binding engagement with a wire in said wire passage and means for effecting relative rotation of said punch and terminal holder members for accomplishing severance of excess wire at the end of the wire opening in a supported terminal.

2. A machine for making solderless connections for electric terminals having wire receiving openings and comprising cooperating punch and holder members having relative movement toward and away from each other, said holder member having means for positioning a terminal with a wire receiving opening therein in line with said punch, a holder for a pin of a size which may be driven into binding engagement with a wire in said passage, said pin holder being arranged to temporarily support a pin between said punch and terminal holder members and in line with the wire passage of the supported terminal, means for effecting relative movement of said punch and terminal holder members to accomplish the driving of a temporarily supported pin into binding engagement with a wire in said wire passage and means for imparting rotary motion to the punch member to apply a severing action on wire projecting from the end of the Wire passage in a supported terminal.

3. A machine for making solderless connections for electric terminals having wire receiving openings and comprising cooperating punch and holder members having relative movement toward and away from each other, said holder member having means for positioning a terminal with a wire receiving opening therein in line with said punch, a holder for a pin of a size which may be driven into binding engagement with a wire in said passage, said pin holder being arranged to temporarily support a pin between said punch and terminal holder members and in line with the wire passage of the supported terminal and means for eifecting relative movement of said punch and terminal holder members to accomplish the driving of a temporarily supported pin into binding engagement with a wire in said Wire passage, said punch member having a Wire severing edge and means for imparting rotation 1 to said member for effecting severance of excess wire at the end of the wire opening in a supported terminal.

4. A machine for making solderless connections for electric terminals having wire receiving openings and comprising cooperating punch and helder; innibrs. haring relative. movement tcward and away fmmeach other, said-,holder memberhavine meansfor positioning a terminal with a wirereceiving; opening therein in line. with Seid punch, a holder for a pin of a, size which may be driven into. binding engagementv with a wire in said passage, said. pin holder being arrangedto temporarily support apin between said punchand terminal holder members and in line, withrthewire passage of the supported terminal end means. flor eiect-ing relative movement of saidy punch and .terminal holder members to accpmplish the, driving of .a temporarily supported pin into binding engagement with a wire in said wire passage, said punch member having a wire severing edgeand means for effecting relative ro.- tationV of; said punch and terminal holder mem-Il bers for accomplishing; severance of excess wire at the end of the wire receiving openingI in. a supported; terrninal.A 1

5. A machine for forming a solderless connection comprisingmeans for supporting a terminal having a wire receiving passage with a wire loosely located therein, a punch in line withl said passage, means for loosely supporting a pin in line with said passage and loosely supported wire, means for effecting approach of said supporting means and punch to thereby accomplish the driving of the fastening pin interposed between said members into the wire receiving passage over the wire disposed therein and means for effecting relative rotation of said supporting means and punch for exerting a twisting-off action on any wire that may project beyond the end of the wire receiving passage.

6. A machine for making solderless connections for electric terminals having contact making end faces, seats countersunk in said contact making end faces and wire receiving passages extending from said seats and comprising cooperating punch and holder members having relative movement toward and away from each other, said holder member having means for Ipositioning a terminal with the wire receiving passage and end seat therein inline with said punch, a holder for a headed pin of a size which may be driven into binding engagement with a wire in said passage, said pin holder being arranged to temporarily support a pin between said punch and terminal holder members in line with the wire passage of a terminal supported in said terminal holder member, means for effecting relative movement of said punch and terminal holder members toward each other to effect driving of a pin temporarily supported in said pin holder into binding engagement with a wire in said Wire passage and to an extent sufficient to force the head of the pin below the contact face of the supported terminal and means operable by said punch at the end of said driving stroke for effecting pinching of excess wire projecting from said Wire passage into said seat in the terminal, for removal of excess wire that might interfere with the contact face of the terminal.

7. A machine for making solderless connections for electric terminalshaving contact making end faces, seats countersunk in said contact making end faces and wire receiving passages extending from said seats and comprising cooperating punch and holder members having relative movement toward and away from each other, said holder member having means for -positioning a terminal with the wire receiving passage and end seat therein in line with said punch, a holder for a headed pin of a size which may be driven into binding engagement with a. wire in said passage, said pin holder being arranged to temporarily support a pin between saidv punch and `terminal holder members in line with the Wire passage of aterminal supported in said terminal holder member, means for effecting relative movement of said punch and Y terminal holder members toward each other to effect driving of a pin temporarily supported in said pin holder into binding engagement with a wire in said wire passage and to an extent suicient to force the head of the pin below the Contact face of the supported terminal, said punch having an end diameter less than the diameter of the seat in the end of the terminal whereby to enter said seat in driving the head of the pin below the contact face to accomplish pinching 01T of excess wire projecting from beneath the head of the driven pin.

SIDNEY M. WEISBERG.

REFERENCES CITED Y The following references are of record in the le of this patent:

UNITED STATES PATENTS" Number Name Date Snee Feb. 21, 1888 Short Sept. 22,' 1891 Daniels Mar. 10, 1896' Holland Feb. 17, 1903 Marchand Mar. '7, 1911 Currie Oct. 10, 1916 Stappler Apr. 1, 1924 McLaughlin Aug. 17, 1926 Fitch A131216, 1929 Phelps et al. Aug. 4, 1931 Barth Apr. 26, 1932 Swoboda Mar. 6, 1934 Hagist Nov. 27, 1934 Wahlstrom Feb. 14, 1939 Double Dec. 19, 1939v De Bella et al June 2, 1942 Michael Aug. 21, 1945 

